Floor element and floor

ABSTRACT

Floor element for use in the gymnastics and/or fitness sector, wherein, in particular for forming a floor with a large surface area, at least one connecting means is provided on least one outer edge to connect the floor element to a further floor element, in particular of the same kind. The floor element is characterised in that the floor element is formed from an elastic, in particular permanently elastic, polyurethane integral foam. In addition the invention relates to a floor formed from a plurality of floor elements according to the invention.

The invention relates to a floor element for use in the gymnastics and/or fitness sector according to the preamble to claim 1. For the formation of a floor with a large surface area, the floor element has toothed areas, on at least one outer edge, for a shape-locking connection to a further floor element.

Floor elements of the type indicated above are used for example in fitness or sports studios. The floor elements laid on a sub-floor protect the sub-floor from damage and wear as well as additionally offering the possibility of an attractive optical design of the floor in a simple and cost-effective way. The floor elements are laid simply on the sub-floor and put together via connecting means to form a floor with a large surface area. In the event of wear or in the case of a desire to change the optical appearance of the floor, the floor can be easily and quickly exchanged. An attractive design of a gymnastics, sports or fitness room which can be easily and quickly adapted to changing requirements can thus be achieved with comparatively simple means.

The floor elements are laid in most cases on the whole surface area of the floor in a gymnastics, sports or fitness room. A known material of such floor elements is for example PVC (polyvinyl chloride).

The floor elements are laid in fitness studios, for example in equipment rooms, in which training equipment is located, or in passage areas. If the floor elements are laid in gymnastics, training or course rooms, for example for group fitness courses, individual gymnastics or training mats providing a soft underlay for each individual sportsman or sportswoman are usually provided for their protection.

It is an object of the invention to provide a floor element for use in the gymnastics and/or fitness sector which can be used in a particularly wide range of applications.

The object is achieved according to the invention through a floor element having the features of claim 1. Preferred embodiments of the invention are indicated in the dependent claims and in the description as well as in the attached figures.

The known floor element is further developed according to the invention by being formed from an elastic polyurethane integral foam.

Polyurethane (PU) is a synthetic material, from which foams can be produced particularly simply. A particular advantage of polyurethane foams is that they can be produced on site in a processing operation from liquid components and be made into a desired shape. All in all, polyurethane foams can be produced economically, even in smaller quantities.

Soft or semi-hard polyurethane foams are characterised by very good permanently elastic and cushioning properties, having a long life, being tough and also absorbing noise. The floor element according to the invention is thus suited in particular for use in areas subject to stress and possibly noise-intensive areas, in which a cushioning floor covering is desired, for example in rooms for group fitness courses.

A core idea of the invention can consequently be seen in making a floor element available which can on the one hand be simply put together with other floor elements to form a floor with a large surface area and which on the other hand forms a soft and cushioning floor underlay. The floor element according to the invention offers on the one hand a protective function for the sub-floor, on which it is laid, and on the other hand a protective function for the people moving on it. The outer edges or edges of the floor element can also be referred to as margins.

Besides a multitude of requirements upon floor mats such as, for example, fire performance, thermal insulation effect, handling and cleaning possibilities, the load-reducing effect thereof upon the human support and movement system is at the forefront from an ergonomic viewpoint, whereby in this respect in particular the conditions with respect to the frequently hard floors, thus having no elastic cushioning effect or limited elastic cushioning effect, are to be improved. In general, the requirements indicated below are to be placed having regard to the load-reducing properties of floor mats:

The pressure distribution under the sole of the foot is to have, as far as possible, no load peaks, within the scope of walking, which would lead to pressure pain on the feet.

The spasmodic load peaks arising during walking within the course of a roll-over process (so-called passive peak forces) shortly after impact of the heel should be as low as possible in order to minimise the load on the joints.

It is known that the joints (foot, knee, hip and vertebral column joints) are the weak points of the human support and movement system. As a result of many years of applying unequal loads and overloading, degenerative changes frequently arise here. In order to reduce the forces acting on the person during standing, walking, running or jumping, the roll-over movement of the foot should be elastically cushioned.

These requirements are fulfilled to a great extent by the floor element according to the invention and a floor put together therefrom.

As a result of the good cushioning properties of the floor element according to the invention, the floor element is particularly kind to joints and in particular knee-friendly for the sportsmen or sportswomen moving on it. The floor element removes the need for an additional training, fitness or gymnastics mat to protect the sportsmen or sportswomen, due to the fact that said floor element can carry out this protection function itself through its cushioning properties. Additional protective mats are not therefore necessary, meaning that for example gymnastics courses can take place without disruptive and time-consuming laying of mats before a course and subsequent storage of individual training mats after the end of the course.

The floor according to the invention made of permanently elastic polyurethane soft integral foam brings together load-reducing and non-slip features as well as offering maximum comfort and protection to athletes. As a result of the robust, cushioning and noise-insulating properties of the floor elements according to the invention with flexibility of layout, a floor is produced having the following advantages:

-   -   Mats are no longer necessary in the training area.     -   The connecting means provided according to the invention         facilitate flexible and individual adaptation of the floor shape         and size.     -   The floor according to the invention has a robust,         cleaning-friendly and non-slip surface and also has advantageous         impact noise-insulating and jolt-cushioning properties.     -   Furthermore the floor according to the invention has cold and         heat insulation properties.     -   Also, the floor according to the invention does not require any         permanent installation and can be removed without difficulties         and re-laid elsewhere.

The floor element according to the invention and the floor according to the invention can be used in fitness and sports studios and also in rehabilitation practices and yoga studios.

The load-reducing effect of a workplace mat made of an extensively similar or identical polyurethane material has been investigated and proven by the Ergonomics Institute of Munich. The effective cushioning behaviour has been shown to act against tiredness and to ensure motivation and performance capability as well as reducing load on joints by up to 60% according to expert reports.

The elasticity of the floor element can be purposefully adjusted to a desired application. Density and hardness can be easily varied during the production process corresponding to the desired properties. The material according to the invention thus offers the possibility of producing floor elements with different properties, for example for different rooms or spaces and applications in a fitness studio.

The floor element according to the invention can advantageously have a maximum temperature load of 80° C., preferably plus/minus 10% of this value, particularly preferably plus/minus 5% of this value and most preferably plus/minus 3% of this value.

Furthermore the floor element according to the invention can advantageously have a compressive strength (40%) with 0.25 Newton per square millimetre, preferably plus/minus 10% of this value, particularly preferably plus/minus 5% of this value and most preferably plus/minus 3% of this value.

The floor element is a foamed component. An integral foam according to the invention is to be understood to mean in particular a material or moulded part with a core made of foam cells and an extensively cell-free outer area.

Accordingly it is preferred according to the invention to form a porous structure inside the floor element. The porous structure forms a soft, elastic foam core which substantially influences the elastic and cushioning properties of the floor element through its cellular structure.

The outer and upper surface of the floor element is preferably extensively or completely closed, that is to say pore-free. The outer shell thus formed, which preferably has a thickness of approximately 1 to 2 mm, offers a hygienic surface, meaning that the floor element is easy to clean. Due to the closed outer shell, the floor element is additionally water-tight. As a result of the outer shell preferably being somewhat more solid with respect to the elastic core, the floor element can withstand greater mechanical stress and is resistant. The material polyurethane (PU) additionally ensures low wear of the surface. A further advantage of polyurethane (PU) is constituted in addition by its good solvent resistance and the possibility of good external painting thereof.

According to a preferred embodiment of the invention the floor element has a single elastic layer which consists of polyurethane integral foam. The floor element is thus a single-layered part. The elastic properties are provided through a single material layer.

The floor element preferably has a Shore A hardness in the range of from 20 to 50, preferably 20 to 30, particularly preferably less than 30. The indicated hardness range offers good protection for the joints along with sufficient support.

The density of the floor element is preferably in the range of from 0.3 to 0.5 g/cm³. The floor element is hereby sufficiently heavy in order to reliably remain lying on the sub-surface without slipping out of place too easily. The density of the floor element is preferably not homogeneous, but instead increases from the outside inwards continuously or successively.

It has been shown that good elastic properties and good manageability during laying can be achieved if the floor element has a thickness in the range of from 5 to 20 mm, preferably 10 to 15 mm.

According to a particularly preferred embodiment, the floor element according to the invention is provided, by way of connecting means, with toothed areas on at least one margin or one edge for shape-locking connection to a further floor element. A particularly reliable connection can be achieved in this way.

In principle, the toothed areas can be designed as desired on the at least one outer edge in order to provide a shape-locking connection to at least one further floor element. A particularly secure connection of individual floor elements can, however, be achieved by the toothed areas being formed to facilitate connection through engagement of one floor element behind a further floor element. The connection achieved through engaging the floor elements behind one another avoids the slipping apart of the connected floor elements. The individual teeth can be formed for example in a dovetail shape or T-shape.

A further advantage of the material polyurethane integral foam is that it has a good feel, and in principle any structures can be designed as desired to the surface of such a moulded component.

According to a further preferred variant of the floor element according to the invention, in order to provide the connecting means, at least one margin or one edge is bevelled in such a way that the margin or the edge can be connected in an overlapping manner to a margin or to an edge of a further floor element which is also bevelled.

In order to prevent the floor element from slipping out of place, it is preferable for a lower side of the floor element to have a structured surface, in particular having pimples and/or grooves.

In order to reduce the risk of slipping by the sportsmen or sportswomen or other persons moving on the floor element, it is preferred for an upper side of the floor element to have a structured surface, in particular having pimples and/or grooves.

The lower side and/or the upper side of the floor element can, however, also be smooth.

A functional and additionally optically attractive floor element can be provided by an upper side of the floor element being at least partially imprinted. The printing can be realised in particular in such a way that zones optically separated from each other are formed. In other words, the floor element has at least two surface zones delimited from each other. In this way, zoning can be provided in order to mark out for example different floor zones of a fitness room such as a running zone and a training zone.

The application of further materials, for example by bonding, to the floor element or to a floor put together from a plurality of floor elements according to the invention can also be advantageous. Further materials which can be used are for example plastic materials, such as films, and/or textile materials, such as felt.

In order to reduce a risk of tripping, a slope is formed preferably on at least one outer edge. The slope allows the floor elements not to be laid over the full area within a whole room, but instead in a targeted manner, for example merely providing sports areas with the floor elements according to the invention. The slope then provides a secure transition at the edge region of the floor to an uncovered part of the sub-floor.

For simple laying of the floor elements to form a floor put together in the manner of a grid, it is preferable for the floor element to have a rectangular, in particular square, shape. In principle any shape is possible which allows complete coverage of the sub-floor. Floor elements of different sizes can also be used. For example floor elements can also be used which have the shape of an equilateral triangle.

According to a preferred embodiment of the invention the floor element is compression-moulded.

According to a further preferred embodiment the invention relates to a floor for use in the gymnastics and/or fitness sector, which is formed from a plurality of floor elements, as described above, which are connected to each other in particular in a shape-locking way. A floor mat with a large surface area is provided by such a floor which at the same time protects the sub-floor from wear and protects sportsmen and sportswomen from injury. A shape-locking connection can be realised via the toothed areas of the individual floor elements. The floor elements are preferably laid in a two-dimensional pattern and each one has a substantially square outer shape.

According to a preferred embodiment the surface of the floor put together from a plurality of floor elements has at least two colour or printed areas delimited from each other in order to provide a zoning, for example for an “athletics area” or a “free space area” in a fitness studio. Markings on the floor element according to the invention and the floor according to the invention can be realised for example in the UV direct to board printing process.

The floor elements according to the invention which can for example have a size of 88 cm×88 cm can for example be loosely bonded with glue for the purpose of laying or during laying. The boards lying one against the other are in this case connected by a strip extending below them and bonded with glue. Depending upon the field of use, the edges in contact with each other can even now be bonded with glue. An even more reliable connection is achieved in this way. It is not necessary to bond the floor according to the invention with glue to the floor lying below.

It is preferable if the margins or the edges of at least two adjacent floor elements contact each other in an edgeless manner. This variant is particularly simple and is not tolerance-critical having regard to the dimensions of the floor elements.

It is preferable if the margins or the edges of at least two adjacent floor elements are connected to each other in a shape-locking way. This variant provides a particularly reliable connection of the floor elements.

It is preferable if the margins or the edges of at least two adjacent floor elements are bonded with glue to each other. This solution also allows a particularly reliable connection of the floor elements.

If is preferable if the margins or the edges of at least two adjacent floor elements over-lap each other. This variant is also particularly simple and is not tolerance-critical having regard to the dimensions of the floor elements.

It is preferable if at least two adjacent floor elements are bonded with glue on a lower side of the floor elements with at least one tape or at least one batten, whereby the tape or the batten overlaps margins or edges of the floor elements in contact with each other. This solution provides the advantage of additional security of the connection of the floor elements.

Where reference is made in this description and the claims to margins or edges of at least two adjacent floor elements, this is intended to mean two directly adjacent margins or edges of two directly adjacent floor elements which are interconnected to form a floor with a surface area which is larger than the surface area of a single one of the two floor elements.

Finally, the use of a floor element according to the invention and/or a floor according to the invention in all the above-described variants for fitness, sports, gymnastics, wellness and/or yoga purposes is claimed. All the advantages described above can then be achieved in practice.

The invention is described in further detail below by reference to the attached, schematic drawing, in which:

FIG. 1 shows a top view of a first embodiment of a floor element according to the invention;

FIG. 2 shows a cross-sectional view of the floor element of FIG. 1; and

FIG. 3 shows a top view of a second embodiment of a floor element according to the invention.

The same components or those having the same effect are characterised in all the figures by the same reference signs.

A floor element 10 according to the invention is an element formed in the shape of a board with a substantially rectangular or square surface. A toothed area 14 with a plurality of teeth 16 as connecting means is formed on at least one outer edge 12 of the floor element 10 in order to connect the floor element 10 to a further floor element in a shape-locking way. Toothed areas are preferably formed on a plurality of outer edges, possibly on all outer edges of the floor element 10. In this way, for example, a training area for functional training can be produced. The floor thus produced consists of a plurality of floor elements 10 which are connected to each other in the manner of jigsaw puzzle pieces. In this way the size and shape of the floor can be extensively freely varied.

The floor can optionally be imprinted with markings. In this respect, a colour layer can be applied to an upper side 20 of the floor element 10. The upper side 20 additionally has a structured surface with individual structural elements 22, for example in the form of pimples, as shown, or in the form of grooves or other structures.

A lower side 32 of the floor element 10 can also have a structured surface with structural elements, for example in the form of pimples or grooves.

The floor element 10 is a foamed component and has a soft foam core 26 inside it with a porous structure 28. The core is completely surrounded by a closed-pore outer shell 24. The outer areas of the floor element 10, in particular the upper side 20 and the lower side 32, each therefore have a closed-pore surface. They form a cell-free edge.

The floor element 10 is formed in its entirety from polyurethane integral foam, that is to say the whole floor element 10 consists of polyurethane integral foam. The floor element 10 is thus a single-layered part, that is to say the pore-free outer shell and the porous inner structure consist of the same material, namely polyurethane.

Markings can optionally be applied to the upper side 20 of the floor element 10. This can be realised for example by a colour print.

The toothed areas 14 can be provided on different outer edges 12 depending upon the design of the floor. For example, the floor element 10 can have opposite outer edges 12 with a toothed area 14, as shown in FIG. 1. The floor area can be produced in this way from linearly joined floor elements 10. In order to avoid a risk of tripping, one or several lateral outer edges 12 can be provided with a slope 38.

A floor element 10 for a corner region of a floor is shown in FIG. 3. The floor element 10 has a respective slope 38 on adjacent outer edges 12. Toothed areas 14 are formed on the further adjacent outer edges 12.

Alternatively, all outer edges 12, or three of the four outer edges 12, can be provided with a toothed area 14. The remaining outer edges 12 can optionally be designed with a slope 38 or with an angular finish.

As a result of the formation of the floor elements 10 from soft or semi-hard foam, the floor is particularly soft and thus kind to joints.

Instead of using the toothed areas described in association with the figures as connecting means, all of the other connecting means described above can also be advantageously used. 

1-23. (canceled)
 24. A floor for use in at least one of: gymnastics or fitness sector, the floor comprising: a plurality of floor elements which are connected to each other and which are formed from an elastic polyurethane integral foam, wherein at least one connecting means to connect a floor element to another floor element is provided on at least one outer edge, wherein the floor elements have a pore-free surface, and wherein edges of adjacent floor elements contact each other in an edgeless manner and are bonded to each other with glue.
 25. The floor according to claim 24, wherein a porous structure is formed inside the floor elements.
 26. The floor according to claim 24, wherein the floor elements have a single elastic layer which consists of polyurethane integral foam.
 27. The floor according to claim 24, wherein the floor elements have a Shore A hardness in a range from 20 to
 50. 28. The floor according to claim 24, wherein the floor elements have a Shore A hardness in a range from 20 to
 30. 29. The floor according to claim 24, wherein the floor elements have a density in a range from 0.3 to 0.5 g/cm³.
 30. The floor according to claim 24, wherein the floor elements have a thickness in a range from 5 to 20 mm.
 31. The floor according to claim 24, wherein a lower side of the floor elements has a structured surface.
 32. The floor according to claim 24, wherein an upper side of the floor elements has a structured surface.
 33. The floor according to claim 24, wherein an upper side of the floor elements is at least partially imprinted.
 34. The floor according to claim 24, wherein the floor elements have at least one of: a rectangular or a square shape.
 35. The floor according to claim 24, wherein the floor elements are compression-moulded.
 36. The floor according to claim 24, wherein at least two adjacent floor elements are bonded with glue on a lower side of the floor elements with at least one tape or at least one batten, and wherein the at least one tape or the at least one batten overlaps at least one of: directly adjacent edges, edges lying directly opposite each other, or edges contacting each other along their extension, of the floor elements.
 37. The floor according to claim 24, wherein the floor elements are formed from a permanently elastic polyurethane integral foam.
 38. The floor according to claim 24, wherein at least one connecting means to connect the floor element to another floor element of the same kind is provided on at least one outer edge.
 39. The floor according to claim 24, wherein an outer shell of the floor elements has a thickness of 1 to 2 mm.
 40. The floor according to claim 24, wherein a lower side of the floor elements has a structured surface having at least one of: pimples or grooves.
 41. The floor according to claim 24, wherein an upper side of the floor elements has a structured surface having at least one of: pimples or grooves.
 42. A method of using the floor according to claim 24 for at least one of: fitness, sports, gymnastics, wellness, or yoga purposes. 